EXHAUST PIPE(w/o DPF) INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:


  • Wear protective gloves and protective glasses when removing the exhaust pipe assembly.

  • The exhaust pipe assembly is extremely hot immediately after the engine has stopped.

  • Confirm that the exhaust pipe assembly has cooled down before removing it.

PROCEDURE


  1. INSTALL TURBINE OUTLET ELBOW LH (w/o Monolithic Converter)


    1. Install a new gasket to the No. 2 turbocharger sub-assembly.

    2. Temporarily install the turbine outlet elbow LH to the No. 2 turbocharger sub-assembly with 3 new nuts.

    3. Temporarily install the No. 2 manifold stay to the transmission assembly with the 3 bolts.

    4. Tighten the 3 nuts of the turbine outlet elbow LH.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

    5. Tighten the 3 bolts of the No. 2 manifold stay.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  2. INSTALL TURBINE OUTLET ELBOW (w/o Monolithic Converter)


    1. Install a new gasket to the turbocharger sub-assembly.

    2. Temporarily install the turbine outlet elbow to the turbocharger sub-assembly with 3 new nuts.

    3. Temporarily install the manifold stay to the transmission assembly with the 3 bolts.

    4. Tighten the 3 nuts of the turbine outlet elbow.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

    5. Tighten the 3 bolts of the manifold stay.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  3. INSTALL MONOLITHIC CONVERTER ASSEMBLY LH (w/ Monolithic Converter)


    1. Install a new gasket to the No. 2 turbocharger sub-assembly.

    2. Temporarily install the monolithic converter assembly LH to the No. 2 turbocharger sub-assembly with 3 new nuts.

    3. Temporarily install the No. 2 manifold stay to the transmission assembly with the 3 bolts.

    4. Tighten the 3 nuts of the monolithic converter assembly LH.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

    5. Tighten the 3 bolts of the No. 2 manifold stay.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  4. INSTALL MONOLITHIC CONVERTER ASSEMBLY (w/ Monolithic Converter)


    1. Install a new gasket to the turbocharger sub-assembly.

    2. Temporarily install the monolithic converter assembly to the turbocharger sub-assembly with 3 new nuts.

    3. Temporarily install the manifold stay to the transmission assembly with the 3 bolts.

    4. Tighten the 3 nuts of the monolithic converter assembly

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

    5. Tighten the 3 bolts of the manifold stay.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  5. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY


    1. w/ EGR System:


      1. w/ Monolithic Converter:

        Install a new gasket and the front No. 2 exhaust pipe assembly to the monolithic converter assembly LH with 2 new nuts.

        Torque:
        54 N*m  { 554 kgf*cm, 40 ft.*lbf }

      2. w/o Monolithic Converter:

        Install a new gasket and the front No. 2 exhaust pipe assembly to the turbine outlet elbow LH with 2 new nuts.

        Torque:
        54 N*m  { 554 kgf*cm, 40 ft.*lbf }

    2. w/o EGR System:


      1. Install a new gasket and the front No. 2 exhaust pipe assembly to the turbine outlet elbow LH with 2 new nuts.

        Torque:
        54 N*m  { 554 kgf*cm, 40 ft.*lbf }

  6. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. w/ EGR System:


      1. w/ Monolithic Converter:

        Install a new gasket and the front exhaust pipe assembly to the monolithic converter assembly with 2 new nuts.

        Torque:
        54 N*m  { 554 kgf*cm, 40 ft.*lbf }

      2. w/o Monolithic Converter:

        Install a new gasket and the front exhaust pipe assembly to the turbine outlet elbow with 2 new nuts.

        Torque:
        54 N*m  { 554 kgf*cm, 40 ft.*lbf }

    2. w/o EGR System:


      1. Install a new gasket and the front exhaust pipe assembly to the turbine outlet elbow with 2 new nuts.

        Torque:
        54 N*m  { 554 kgf*cm, 40 ft.*lbf }

  7. INSTALL CENTER EXHAUST PIPE ASSEMBLY


    1. Check the free length.


      1. A01WVK4

        Using a vernier caliper, measure the free length of the compression spring.

        Free length
        43 mm (1.69 in.)

        If the free length is less than the minimum, replace the compression spring.

    2. Connect the center exhaust pipe assembly to the 3 exhaust pipe supports.

    3. Install 2 new gaskets to the front exhaust pipe assembly and front No. 2 exhaust pipe assembly.

    4. Install the center exhaust pipe assembly to the front exhaust pipe assembly and front No. 2 exhaust pipe assembly with the 4 bolts and 2 compression springs.

      Torque:
      for center exhaust pipe assembly and front exhaust pipe assembly
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for center exhaust pipe assembly and front No. 2 exhaust pipe assembly
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  8. INSTALL TAILPIPE ASSEMBLY


    1. A01WTYOE04
      Text in Illustration
      *1 Gasket
      *a Top
      *b LH Side
      B0018FC Front

      Connect the tailpipe assembly to the 2 exhaust pipe supports.

    2. Install a new gasket to the center exhaust pipe assembly.

    3. Connect the tailpipe assembly to the center exhaust pipe assembly with a new clamp.

      Tech Tips

      Install the clamp within the angle range shown in the illustration.

    4. Tighten the bolt.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  9. INSPECT FOR EXHAUST GAS LEAK

    Click here

  10. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover to the frame with the 6 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  11. INSTALL FRONT FENDER APRON SEAL REAR LH


    1. Install the front fender apron seal rear LH with the 4 clips.

  12. INSTALL FRONT FENDER APRON SEAL REAR RH


    1. Install the front fender apron seal rear RH with the 4 clips.